Conveyors including sensors for detecting error conditions associated with products traveling on the conveyors

ABSTRACT

In some embodiments, methods and systems are provided that include interconnected conveyors including multiple sensors configured to detect identifying characteristics and physical characteristics of the products traveling on the conveyors. The product-associated information that is detected by the sensors is analyzed relative to predefined product-associated identifying characteristics and physical characteristics stored in a database, and an error signal is generated if the actual, sensor-obtained product identifying characteristics and/or physical characteristics, do not correspond to the predefined, database-stored product identifying characteristics and/or physical characteristics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/882,692, filed on Jan. 29, 2018, which claims the benefit of U.S.Provisional App. No. 62/455,121, filed Feb. 6, 2017, each of which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

This invention relates generally to sorting products using conveyorsand, in particular, to systems and methods for sorting products usingconveyors having multiple sensors.

BACKGROUND

Retailers routinely transport products within product distributionfacilities using conveyor systems. For example, products and/or packagesare routinely transported from a product packaging or sorting area viaconveyors to a product loading area (e.g., into a delivery vehicle). Itis not uncommon for products traveling on such conveyors and destinedfor delivery to a consumer to be damaged, for example, as a result ofsome manipulation by a worker at the product distribution facility, oras a result of being defective, or as a result of not being maintainedat its proper storage/transportation temperature. If such anomalies inthe products are not detected prior to such defective and/or damagedproducts being loaded into delivery vehicles and delivered to consumers,the consumers not only become unhappy with the retailer and may notorder from the retailer again, but also return the defective and/ordamaged products back to the retailer, thereby increasing the retailer'scost and reducing the retailer's profits.

BRIEF DESCRIPTION OF THE DRAWINGS

Disclosed herein are embodiments of systems, apparatuses, and methodspertaining to sorting and tracking products at a product distributionfacility includes a plurality of interconnected conveyors configured tomove the products. This description includes drawings, wherein:

FIG. 1 is a diagram of a system of sorting and tracking products at aproduct distribution facility includes a plurality of interconnectedconveyors configured to move the products in accordance with someembodiments;

FIG. 2 is a functional diagram of an exemplary electronic inventorymanagement device usable with the system of FIG. 1 in accordance withsome embodiments.

FIG. 3 is a flow chart diagram of a process of sorting and trackingproducts at a product distribution facility includes a plurality ofinterconnected conveyors configured to move the products in accordancewith some embodiments.

Elements in the figures are illustrated for simplicity and clarity andhave not been drawn to scale. For example, the dimensions and/orrelative positioning of some of the elements in the figures may beexaggerated relative to other elements to help to improve understandingof various embodiments of the present invention. Also, common butwell-understood elements that are useful or necessary in a commerciallyfeasible embodiment are often not depicted in order to facilitate a lessobstructed view of these various embodiments of the present invention.Certain actions and/or steps may be described or depicted in aparticular order of occurrence while those skilled in the art willunderstand that such specificity with respect to sequence is notactually required. The terms and expressions used herein have theordinary technical meaning as is accorded to such terms and expressionsby persons skilled in the technical field as set forth above exceptwhere different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles ofexemplary embodiments. Reference throughout this specification to “oneembodiment,” “an embodiment,” or similar language means that aparticular feature, structure, or characteristic described in connectionwith the embodiment is included in at least one embodiment of thepresent invention. Thus, appearances of the phrases “in one embodiment,”“in an embodiment,” and similar language throughout this specificationmay, but do not necessarily, all refer to the same embodiment.

Generally speaking, pursuant to various embodiments, systems and methodsare provided for sorting and tracking products at a product distributionfacility.

In one embodiment, a system for sorting and tracking products at aproduct distribution facility includes a plurality of interconnectedconveyors configured to move the products, a first sensor positionedproximate a product advancement surface of at least one of the conveyorsand configured to detect at least one identifying characteristic of atleast one product moving on the product advancement surface, and asecond sensor positioned proximate the product advancement surface andconfigured to detect at least one physical characteristic of the atleast one product moving on the product advancement surface. The systemfurther includes an electronic database storing inventory managementdata including: data indicating predefined identifying characteristicand physical characteristic information associated with the at least oneproduct, the predefined identifying characteristic and physicalcharacteristic information corresponding to the at least one productwhen in a new condition and undamaged; data indicating actualidentifying characteristic information associated with the at least oneproduct, the actual identifying characteristic information correspondingto the at least one product when detected by the first sensor duringmovement of the at least one product along the product advancementsurface; and data indicating actual physical characteristic informationassociated with the at least one product, the actual physicalcharacteristic information corresponding to the at least one productwhen detected by the second sensor during movement of the at least oneproduct along the product advancement surface. The system furtherincludes a processor-based electronic inventory management device incommunication with the first and second sensors and the electronicdatabase. The electronic inventory management device is configuredobtain the inventory management data stored in the electronic databaseand, based on the obtained inventory management data, to: compare thedata indicating the actual identifying characteristic informationassociated with the at least one product detected by the first sensorduring movement on the product advancement surface to the dataindicating the predefined identifying characteristic informationassociated with the at least one product in order to determine anidentity of the at least one product detected by the first sensor;compare the data indicating the actual physical characteristicinformation associated with the at least one product detected by thesecond sensor during movement on the product advancement surface to thedata indicating the predefined physical characteristic informationassociated with the at least one product in order to verify that theidentity of the at least one product and that the condition of the atleast one product detected by the second sensor is new and undamaged;and redirect movement of the at least one product detected by the firstand second sensors on the product advancement surface of the at leastone of the conveyors in response to a determination, by the electronicinventory management device, that a verification of the identity of theat least one product failed or that the at least one product is not in anew condition or is in a damaged condition.

In another embodiment, a method for sorting and tracking products at aproduct distribution facility includes: providing a plurality ofinterconnected conveyors configured to move the products; providing afirst sensor positioned proximate a product advancement surface of atleast one of the conveyors and configured to detect at least oneidentifying characteristic of at least one product moving on the productadvancement surface; providing a second sensor positioned proximate theproduct advancement surface and configured to detect at least onephysical characteristic of the at least one product moving on theproduct advancement surface; providing an electronic database storinginventory management data including: data indicating predefinedidentifying characteristic and physical characteristic informationassociated with the at least one product, the predefined identifyingcharacteristic and physical characteristic information corresponding tothe at least one product when in a new condition and undamaged; and dataindicating actual identifying characteristic information associated withthe at least one product, the actual identifying characteristicinformation corresponding to the at least one product when detected bythe first sensor during movement of the at least one product along theproduct advancement surface; data indicating actual physicalcharacteristic information associated with the at least one product, theactual physical characteristic information corresponding to the at leastone product when detected by the second sensor during movement of the atleast one product along the product advancement surface; and providing aprocessor-based electronic inventory management device in communicationwith the first and second sensors and the electronic database, theelectronic inventory management device being configured obtain theinventory management data stored in the electronic database and, basedon the obtained inventory management data, to: compare the dataindicating the actual identifying characteristic information associatedwith the at least one product detected by the first sensor duringmovement on the product advancement surface to the data indicating thepredefined identifying characteristic information associated with the atleast one product in order to determine an identity of the at least oneproduct detected by the first sensor; compare the data indicating theactual physical characteristic information associated with the at leastone product detected by the second sensor during movement on the productadvancement surface to the data indicating the predefined physicalcharacteristic information associated with the at least one product inorder to verify that the identity of the at least one product and thatthe condition of the at least one product detected by the second sensoris new and undamaged; and redirect movement of the at least one productdetected by the first and second sensors on the product advancementsurface of the at least one of the conveyors in response to adetermination, by the electronic inventory management device, that averification of the identity of the at least one product failed or thatthe is not in a new condition or is in a damaged condition.

FIG. 1 shows an embodiment of a system 100 for sorting and trackingproducts 190. The exemplary system 100 shown in FIG. 1 for simplicity ofillustration with only three conveyors 110 a-c and three products 190a-190 c thereon, but it will be appreciated that the system 100 mayinclude less conveyors (e.g., 1 or 2), or more conveyors (e.g., from 4,10, 20, 30, 50, 100, or more) depending on the size of the productdistribution facility where the conveyor system 100 is installed, anddepending on the number of products 190 passing through the system 100.By the same token, while each conveyor 110 a-110 c is illustrated inFIG. 1 as having one product 190 a-190 c thereon, respectively, it willbe appreciated that each of the conveyors 110 a-110 c may concurrentlytransport more than one product 190 a-190 c (e.g., dozens and/orhundreds of products, depending on the length of the conveyor). Inaddition, while this application refers to products 190 a-190 c and thesorting of products 190 a-190 c, it will be appreciated that theconveyor system 100 may be used to transport products that are retainedin packages, boxes, and/or totes, and/or loose products that are notpackaged. Further, the size of the products 190 a-190 c in FIG. 1 hasbeen shown by way of example only, and it will be appreciated that theconveyors may transport many different products 190 a-190 c having manydifferent sizes and shapes.

The exemplary conveyors 110 a-110 c of FIG. 1 can be horizontallyadjacent or vertically stacked relative to one another. The conveyors110 a-110 c each have a product advancement surface 120 a-120 cconfigured to move one or more products 190 a-190 c in one or moredirections indicated by the arrows. The product advancement surface 120a-120 c of the conveyors 110 a-110 c may be comprised of a singleconveyor belt surface (horizontal (as shown) or inclined), or may beinstead comprised of a series of two or more independently movableconveyor belt surfaces (horizontal or inclined). The conveyors 110 a-110c may be belt conveyors, chain conveyors, or the like and may have acontinuous, uninterrupted product advancement surface 120 a-120 c, ormay have a product advancement surface 120 a-120 c that includes one ormore interruptions at the transitions between the distinct conveyorsurfaces.

In the embodiment shown in FIG. 1, the system 100 further includestransfer conveyors 130 a and 130 b interconnecting the conveyors 110a-110 c and providing multiple transfer nodes where the products 190a-190 c may be transferred between the conveyors 110 a-110 c. Similarlyto the product advancement surfaces 120 a-120 c of conveyors 110 a-110c, the transfer conveyors 130 a-130 b may be independently movablerelative to one another. As such, either one of the transfer conveyors130 a-130 b may be stopped while the other one is permitted to move. Itwill be appreciated that each of the transfer conveyors 130 a-130 b maybe movable in one direction only (e.g., to permit for product transferfrom conveyor 110 a to conveyor 110 b, but not vice versa), or may bemovable in two directions (e.g., to permit for product transfer fromconveyor 110 a to conveyor 110 b and from conveyor 110 b to conveyor 110a).

In the system 100 shown in FIG. 1, the transfer conveyors 130 a-130 bare shown as being oriented in a direction perpendicular to therespective product advancement surfaces 120 a-120 c that transferconveyors 130 a-130 b interconnect. However, it will be appreciated thatthe transfer conveyors 130 a-130 b may be oriented in a direction thatis not perpendicular (e.g., at a 30 degree, 60 degree, 120 degree, or150 degree angle) relative to their respective product advancementsurfaces 120 a-120 c. Also, while conveyors 110 a and 110 b areinterconnected by one transfer conveyor 130 a and conveyors 110 b and110 c are interconnected by one transfer conveyor 130 b, it will beappreciated that each conveyor 110 a-110 c may be connected by more thanone transfer conveyor to more than one other conveyors, and that each ofthe conveyors 110 a-110 c may include two or more (e.g., 5, 10, 25, 50,100, or more) transfer conveyors 130 a-130 b coupled thereto, dependingon the length of the conveyors 110 a-110 c, and the throughput needs ofa product distribution facility where system 100 is implemented and thesize of the system 100.

In order to effectuate the directional movement of the productadvancement surface 120 a-120 c of the conveyors 110 a-110 c and themovement of products 190 a-c thereon, the exemplary system 100illustrated in FIG. 1 includes a conveyor control unit 140 a-140 ccoupled (e.g., electrically) to each respective conveyor 110 a-110 c.The conveyor control units 140 a-140 c can be located at or near theconveyors 110 a-110 c as shown in FIG. 1, or may be built into and/or onthe conveyors 110 a-110 c. In some embodiments, the conveyor controlunits 140 a-140 c are configured to receive a signal from an electronicinventory management device 180 (which will be described in more detailbelow) and, in response to receipt of such a signal, to either causetheir respective product advancement surface 120 a-120 c (and/or theirrespective transfer conveyor 130 a-130 c) to move in the direction shownby directional arrows in FIG. 1 (or in an opposite direction), or tostop. It will be appreciated that each of the transfer conveyors 130a-130 c, instead of being controlled by the conveyor control units 140a-140 c, can have their own respective conveyor control units coupledthereto.

The exemplary system 100 shown in FIG. 1 includes a first sensor 150positioned proximate the product advancement surface 120 a of theconveyor 110 a. In some aspects, the sensor 150 is configured to detectat least one identifying characteristic of a product 190 a moving on theproduct advancement surface 120 a. According to some embodiments, thesensor 150 can include one or more sensors including but not limited toa motion-detecting sensor, a photo sensor, a radio frequencyidentification (RFID) sensor, an optical sensor, a barcode sensor, and adigital camera sensor. The system 100 also includes a second sensor 155positioned proximate the product advancement surface 120 a of theconveyor 110 a. In some aspects, the sensor 155 is configured to detectat least one physical characteristic of the product 190 a moving on theproduct advancement surface 120 a. According to some embodiments, thesensor 155 can include one or more sensors including but not limited toa weight sensor, a volumetric sensor, size sensor, a 3-D sensor, agas/chemical sensor, an infrared sensor, a thermal sensor, or the like.

In some embodiments, the system 100 includes a third sensor 160positioned proximate the product advancement surface 120 a of theconveyor 110 a and configured to detect the presence and/or location ofthe product 190 a moving on the product advancement surface 120 a ofconveyor 110 a. According to some embodiments, the sensor 160 caninclude one or more sensors including but not limited to amotion-detecting sensor, physical contact sensor, barcode-scanningsensor, RFID-detecting sensor, digital camera sensor, or the like.

In some embodiments, the sensors 150 and/or 160 are configured to scanidentifying indicia located on the product 190 a or on the packagingcontaining the product 190 a. The identifying indicia on the product 190a that may be scanned by the sensor 160 may include, but is not limitedto: two dimensional barcode, RFID, near field communication (NFC)identifiers, ultra-wideband (UWB) identifiers, Bluetooth identifiers,images, or other such optically readable, radio frequency detectable orother such code, or combination of such codes.

In some aspects, a product identifying characteristic-detecting sensor150 in the form of a camera provides for image analysis of the product190 a, text recognition on the product 190 a (e.g., product name),and/or pattern recognition on the product 190 a (e.g., color pattern orbarcode pattern) as the product 190 a is moving on the productadvancement surface 120 a. For example, a camera-based sensor 150monitoring a product 190 a that is a cardboard case (normally having auniform light brown color pattern) moving along the product advancementsurface 120 a can acquire a visual pf the product 190 a (i.e., cardboardcase) and detect a darker patch in the cardboard case, which, whentransmitted to the electronic inventory management device 180, can beinterpreted by the control circuit 210 of the electronic inventorymanagement device 180 as a hole in the cardboard case, which can lead toa redirection of the product 190 from its initial route on the conveyor110 a either to product sorting or disposal.

In some aspects, a tolerated damage or anomaly threshold can bepreprogrammed into the control circuit 210 of the electronic inventorymanagement device 180. Such a threshold, for example, can be apercentage of area of the cardboard case with unexpected (i.e., darkerpatch) color. In other words, if one or more surfaces of the product 190a (or product packaging) are detected to have an anomaly or mismatch inmore than a tolerated preset percentage (e.g., 5%, 10%, 20%) of itssurface area, the control circuit 210 is programmed to divert theproduct 190 a from its original route along the product advancementsurface 120 a of conveyor 110 a to a different conveyor (e.g., 110 b)for transporting the product 190 back to a product sorting/packagingarea. In one aspect, such a redirection of the product 190 a isaccompanied by an alert signal transmitted from the electronic inventorymanagement device 180 to a hand-held electronic device of a worker atthe product distribution facility. In some aspects, a camera-basedsensor 150 captures an image of a product 190 that visually indicates aliquid spill on the product advancement surface 120 a, a granule orparticle presence on the product advancement surface 120 a, a productbody deformation such as an ice cream melting, for example, (in someaspects, by more than a tolerated deformation percentage (e.g., 10%,20%, etc.) threshold), or loose items that fell out of their originalpackaging.

In certain implementations, the camera-based sensor 150 is configured tocapture an image of the product 190 traveling on the product advancementsurface 120 a and to compress the captured image prior to transmittingthe compressed image to the electronic database 170 for storage andlater analysis by the control circuit 210 of the inventory managementdevice 180. This image compression by the camera-based sensor 150advantageously reduces the storage requirements of the electronicdatabase 170 (as compared to capturing and transmitting full-sizeimages), and advantageously reduces the processing power required of thecontrol circuit 210 to process the compressed image (as compared to thefull-size image) when attempting to detect any physical characteristicanomalies of the product 190 a-190 c based on processing the imagecaptured by the camera-based sensor 150 and stored in the electronicdatabase 170.

In one aspect, a product physical characteristic-detecting sensor 155 isa weight sensor in the form of a plate or a roller positioned under theproduct advancement surface 120 a that provides for the measurement ofthe weight of the product 190 a as the product 190 a passes over theweight sensor. In one aspect, the weight sensor 155 is in the form ofone or more piezoelectric sensors embedded into the product advancementsurface 120 a of the conveyor 110 a. In some embodiments, a weight of aproduct 190 a detected by the sensor 155 is transmitted by the sensor155 to the electronic inventory management device 180 and correlated bythe electronic inventory management device 180 to a predefined weight ofthe product 190 when the product 190 a is new and undamaged (whichpredefined weight is obtained from the electronic database 170). If thecomparison, by the control circuit 210 of the electronic inventorymanagement device 180, of the actual weight of the product 190 a (or ofmultiple units of product 190 a packaged in a case) that is measured bythe sensor 155 to the predefined weight of the product 190 a (ormultiple units of the product 190 a packaged in a case) when the product190 a is new and undamaged indicates a discrepancy that exceeds acertain tolerated threshold (e.g., 5%, 10%, etc.) between the twoweights, an error condition is triggered by the control circuit 210 ofthe electronic inventory management device 180, which, in someembodiments, results in the redirection of the product 190 a fromconveyor 110 a to conveyor 110 b.

In one aspect, a product physical characteristic-detecting sensor 155 isan infrared and/or a thermal sensor that measures the temperature of theproduct 190 a and/or insulation integrity of the packaging of theproduct 190 a as the product 190 a is moving on the product advancementsurface 120 a. In some embodiments, a temperature of a product 190(e.g., a temperature-sensitive perishable product) detected by thesensor 155 is transmitted by the sensor 155 to the electronic inventorymanagement device and correlated by the electronic inventory managementdevice 180 to a predefined temperature (e.g., 32° F.) required for theproduct 190 a to maintain its desired texture or freshness (whichpredefined temperature is obtained from the electronic database 170). Ifthe comparison, by the control circuit 210 of the electronic inventorymanagement device 180, of the actual temperature of the product 190 athat is measured by the sensor 155 to the predefined temperature of theproduct 190 a when the product 190 a is at its proper storagetemperature indicates a discrepancy that exceeds a certain toleratedthreshold (e.g., 1° F., 2° F., 3° F., 5° F., 10° F., etc.) between thetwo temperatures, an error condition is triggered by the control circuit210 of the electronic inventory management device 180.

In one embodiment, the product physical characteristic-detecting sensor155 is a 3D scanner or sensor configured to detect and/or measure theshapes and/or dimensions of the product 190 a moving on the productadvancement surface 120 a and/or distances between the products movingon the product advancement surface 120 a. In one aspect, shape or sizeof a product 190 a detected by the 3-D sensor 155 is transmitted by thesensor 155 to the electronic inventory management device 180 andcorrelated by the electronic inventory management device 180 to apredefined shape or size of the product 190 when the product 190 a isnew and undamaged (which predefined shape or size is obtained from theelectronic database 170). If the comparison, by the control circuit 210of the electronic inventory management device 180, of the actual shapeor size of the product 190 a (or of multiple units of product 190 apackaged in a case) that is measured by the sensor 155 to the predefinedshape or size of the product 190 a (or multiple units of the product 190a packaged in a case) when the product 190 a is new and undamagedindicates a discrepancy that exceeds a certain tolerated threshold(e.g., 5%, 10%, etc.) between the two shapes or sizes, an errorcondition is triggered by the control circuit 210 of the electronicinventory management device 180, which, in some instances, results inthe redirection of the product 190 a from conveyor 110 a to conveyor 110b.

In one embodiment, the product physical characteristic-detecting sensor155 is a chemical or gas sensor configured to detect a gas (e.g.,ethylene gas, methane, etc.) or chemical odor released by the product190 (e.g., seafood, meat, dairy, etc.) when the product 190 is spoiled.For example, in some aspects, if an analysis, by the control circuit 210of the electronic inventory management device 180, of the gas detectedby the sensor 155 exceeds a certain tolerated threshold for that gas(e.g., 10 ppb, 30 ppb, 50 ppb, 100 ppb, etc.), an error condition istriggered by the control circuit 210 of the electronic inventorymanagement device 180, which, in some cases, results in the redirectionof the product 190 a from conveyor 110 a to conveyor 110 b.

It will be appreciated that in some embodiments, equivalents of sensors,150 a-150 c can be positioned proximate the product advancement surfaces120 b-120 c, which has not been shown in FIG. 1 for ease ofillustration. In addition, while FIG. 1 shows the sensors 150 a-150 c asbeing positioned adjacent and above the conveyor 110 a, it will beappreciated that the sensors 150 a-b may be positioned below, and on oneor both sides of the conveyor 110 a. In addition, the locations of thesensors 150 a-150 c relative to the conveyor 110 a in FIG. 1 are by wayof example only, and the sensors 150 a-150 c may be placed at differentlocations, as well as multiple repeating locations, along the productadvancement surface 120 a of conveyor 110 a. Furthermore, it will beappreciated that one or more of the sensors 150 a-150 c can bephysically incorporated (e.g., coupled to, embedded, etc.) into thephysical structure of the conveyor 110 a and/or product advancementsurface 120 a.

In the embodiment shown in FIG. 1, the system 100 includes an electronic(inventory management) database 170. In some embodiments, the electronicinventory management device 180 and the electronic database 170 may beimplemented as two separate physical devices in the same physicallocation as the conveyors 110 a-110 c of system 100 as shown in FIG. 1.It will be appreciated, however, that the electronic inventorymanagement device 180 and the electronic database 170 may be implementedas a single physical device, and may be located at different locationsrelative to each other and relative to the conveyors 110 a-110 c. Insome embodiments, the electronic database 170 may be stored, forexample, on non-volatile storage media (e.g., a hard drive, flash drive,or removable optical disk) internal or external to the electronicinventory management device 180, or internal or external to computingdevices distinct from the electronic inventory management device 180. Insome embodiments, the electronic database 170 may be cloud-based.

In some embodiments, the exemplary electronic database 170 of FIG. 1 isconfigured to store electronic data associated with the products 190a-190 c moving on the conveyors 110 a-110 c and which is acquired by oneor more of the sensors 150, 155, and 160. Some exemplary electronic datathat may be stored in the electronic database 170 includes but is notlimited to: identification of the products 190 a-190 c (e.g., barcodeand/or other identifying indicia); date of purchase of the products 190a-190 c (if applicable); price of purchase of the products 190 a-190 c(if applicable); number of units of the products 190 a-190 c to betransported via the conveyors 110 a-110 c; delivery destinationpertaining to the products 190 a-190 c; delivery vehicle loadinglocation and delivery vehicle scheduling information associated with theproducts 190 a-190 c; and information (e.g., name, address, paymentinformation, etc.) pertaining to one or more consumers (or otherintended recipients) associated with the products 190 a-c.

In some configurations, the inventory management data stored by theelectronic database 170 includes order information associated with theproduct 190 a moving on the product advancement surface 120 a ofconveyor 110, for example, when the product 190 a is moving on theconveyor 110 at the product distribution facility for the purpose ofbeing transported to a delivery truck to be delivered to the customerwho ordered this product 190 a. Here, the control circuit 210 of theelectronic inventory management device 180 is programmed to obtain theorder information associated with the product 190 a from the electronicdatabase 170 after the identity (e.g., barcode) and the condition (e.g.,new and undamaged) of the product 190 are successfully verified by thecontrol circuit 210, and to determine whether the verified identity ofthe product 190 a moving on the product advancement surface 120 a of theconveyor 110 a is consistent with the order information associated withthe product 190 a obtained by the control circuit 210 of the electronicinventory management device 180 from the electronic database 170.

In some embodiments, the inventory management data stored by theelectronic database 170 includes but is not limited to: data indicatingone or more predefined identifying characteristics associated with theproducts 190 a-190 c; data indicating one or more predefined physicalcharacteristic associated with the products 190 a-190 c; data indicatingactual identifying characteristic information associated with theproducts 190 a-190 c; and data indicating actual physical characteristicinformation associated with the products 190 a-190 c. In some aspects,the predefined identifying characteristic and physical characteristicinformation each correspond to the products 190 a-190 c when they are ina new condition and undamaged; the actual identifying characteristicinformation corresponds to the products 190 a-190 c when detected by thesensor 150 during movement of the products 190 a-c along theirrespective product advancement surface 120 a-120 c; and the actualphysical characteristic information corresponding to the products 190a-190 c when detected by the sensor 155 during movement of the products190 a-190 c along their respective product advancement surface 120 a-120c.

In some embodiments, the inventory management data stored by theelectronic database 170 further includes the error conditions detectedby the sensor 155 during a scan of the products 190 a-190 c. Forexample, in some aspects, each time the sensor 155 triggers an errorsignal based on detecting an apparent anomaly in the physicalcharacteristic of the scanned product 190 a-190 c (e.g., weight, size,shape, temperature, etc.), this error signal is communicated by thesensor 155 to the electronic database 170 for storage. The error signalsstored in the electronic database 170 may be used in someimplementations as data that provides metrics and trends that may beused (e.g., by supervisory personnel) to analyze the quality of the workproduct of the workers that are tasked with loading the products 190a-190 c onto the conveyors 110 a-110 c.

For example, a statistically significant high number of error signalsassociated with the tasks performed by a given worker as compared to theother workers working assigned to the conveyors 110 a-110 c may beindicative that this worker is not using appropriate care when handlingthe products 190 a-190 c during the loading of the products 190 a-190 conto the conveyors 110 a-110 c. By the same token, the error signalsstored in the electronic database 170 may be used in someimplementations as data that provides metrics and trends indicative ofthe quality of products 190 a-190 c provided by variousmanufacturers/distributors/delivery services. For example, astatistically high number of error conditions (e.g., weight anomalyassociated with a possible leak, etc.) detected with a given packagedproduct may be indicative of the poor quality of the packaging by themanufacturer of this product and/or of a lack of care used by thedelivery service when transporting this product.

In some embodiments, the inventory management data stored by theelectronic database 170 further includes exception handling datareflecting each instance when sensor 155 falsely triggers an errorsignal indicative that one or more of the scanned products 190 a-190 cdeviates beyond the tolerated threshold from the predefined defaultphysical characteristics of the products 190 a-190 c associated with theproducts 190 a-190 c being in a new and undamaged condition and/or attheir desired/required storage temperature. In other words, each time anerror condition is detected by the sensor 155 during a scan of theproducts 190 a-190 c and a product 190 a-190 c is diverted from itsoriginally intended travel path along the conveyors 110 a-110 c, boththe error condition and the accompanying travel diversion of theanomaly-associated product 190 a-190 c are transmitted to and recordedin the electronic database 170.

In some aspects, if a product 190 a-190 c diverted from its originaltravel path is determined later on (e.g., at the product loadinglocation, disposal location, etc.) by a worker not to be damaged basedon a physical inspection, the worker would then enter exception handlingdata into the electronic database 170 (e.g., via a hand-held device or adesktop computer). This exception handling data entered by the workerwould be associated in the electronic database 170 with the sensor 155that triggered the error signal, thereby providing the system 100 withexception error handling recordation and metric generation options. Incertain aspects, the system 100 is enabled with machine-learningfunctions associated with exception error handling, where the controlcircuit of the electronic inventory management device 180 is programmedto determine that a given sensor 155 is faulty based on detecting astatistically significant number of false positive error alertsgenerated by that sensor 155 with respect to the products 190 a-190 cthat are later contradicted by a physical inspection of the products 190a-190 c by the workers.

The exemplary system 100 of FIG. 1 further includes an electronicinventory management device 180 configured to communicate with theconveyor control units 140 a-140 c, sensors 150, 155, 166, andelectronic database 170. The electronic inventory management device 180may be a stationary or portable electronic device, for example, adesktop computer, a laptop computer, a tablet, a mobile phone, or anyother electronic device including a processor-based control circuit(i.e., control unit). In the embodiment of FIG. 1, the electronicinventory management device 180 is configured for data entry andprocessing as well as for communication with other devices of system 100via the network 115 which may be a wide-area network (WAN), a local areanetwork (LAN), a personal area network (PAN), a wireless local areanetwork (WLAN), or any other internet or intranet network, orcombinations of such networks. The electronic inventory managementdevice 180 may be located at the same physical location as the conveyors110 a-110 c and/or the electronic database 170, or may be located at aremote physical location relative to the conveyors 110 a-110 c and/orthe electronic database 170.

With reference to FIG. 2, the electronic inventory management device 180configured for use with exemplary systems and methods described hereinmay include a control unit or control circuit 210 including a processor(e.g., a microprocessor or a microcontroller) electrically coupled via aconnection 215 to a memory 220 and via a connection 225 to a powersupply 230. The control circuit 210 can comprise a fixed-purposehard-wired platform or can comprise a partially or wholly programmableplatform, such as a microcontroller, an application specificationintegrated circuit, a field programmable gate array, and so on. Thesearchitectural options are well known and understood in the art andrequire no further description here.

This control circuit 210 can be configured (for example, by usingcorresponding programming stored in the memory 220 as will be wellunderstood by those skilled in the art) to carry out one or more of thesteps, actions, and/or functions described herein. In some embodiments,the memory 220 may be integral to the processor-based control circuit210 or can be physically discrete (in whole or in part) from the controlcircuit 210 and is configured non-transitorily store the computerinstructions that, when executed by the control circuit 210, cause thecontrol circuit 210 to behave as described herein. (As used herein, thisreference to “non-transitorily” will be understood to refer to anon-ephemeral state for the stored contents (and hence excludes when thestored contents merely constitute signals or waves) rather thanvolatility of the storage media itself and hence includes bothnon-volatile memory (such as read-only memory (ROM)) as well as volatilememory (such as an erasable programmable read-only memory (EPROM))).Accordingly, the memory and/or the control unit may be referred to as anon-transitory medium or non-transitory computer readable medium.

The control circuit 210 of the electronic inventory management device180 is also electrically coupled via a connection 235 to an input/output240 that can receive signals from, for example, from the sensors 150,155, and/or 160, and/or from the conveyor control units 140 a-140 c(e.g., a signal indicating which product 190 a-190 c has beentransferred from which conveyor 110 a-110 c and to which conveyor 110a-110 c), and/or from the electronic database 170, and/or from anotherelectronic device (e.g., a hand-held electronic device of a worker) overthe network 115. The input/output 240 of the electronic inventorymanagement device 180 can also send signals to the conveyor controlunits 140 a-140 c indicating which product 190 a-190 c to transfer fromwhich conveyor 110 a-110 c and to which conveyor 110 a-110 c.

The processor-based control circuit 210 of the electronic inventorymanagement device 180 shown in FIG. 2 is electrically coupled via aconnection 245 to a user interface 250, which may include a visualdisplay or display screen 260 (e.g., LED screen) and/or button input 270that provide the user interface 250 with the ability to permit anoperator (e.g., worker at a product distribution facility where thesystem 100 is implemented, or a worker at a remote control center) ofthe electronic inventory management device 180 to manually control theelectronic inventory management device 180 by inputting commands viatouch-screen and/or button operation and/or voice commands. The userinterface 250 of the electronic inventory management device 120 may alsoinclude a speaker 280 that provides audible feedback (e.g., alerts) tothe user. Possible commands may, for example, cause the electronicinventory management device 180 to send out a signal to the conveyorcontrol unit 140 a-140 c of a conveyor 110 a-110 c in order to cause aproduct 190 a-190 c to be transferred from one conveyor (e.g., 110 a) toanother conveyor (e.g., 110 b). For example, such manual control by anoperator may be via the user interface 250 of the electronic inventorymanagement device 180, via another electronic device of the operator, orvia another user interface and/or switch, and may include an option tooverride the initial routing for the products 190 a-190 c on theconveyors 110 a-110 c preset by the electronic inventory managementdevice 180, and to set new routing for the products 190 a-190 c (e.g.,for which evidence of damage or other unacceptable condition wasdetected by the sensors 155) on the conveyors 110 a-110 c. It will beappreciated that the performance of such functions by theprocessor-based control circuit 210 of the electronic inventorymanagement device 180 is not dependent on a human operator, and that thecontrol circuit 210 may be programmed to perform such functions withouta human operator.

In some embodiments, the control circuit 210 of the electronic inventorymanagement device 180 is configured obtain the aforementioned inventorymanagement data stored in the electronic database 170. In some aspects,based on the inventory management data obtained from the electronicdatabase 170 in association with a given product 190 a, the controlcircuit 210 of the electronic inventory management device 180 isprogrammed to compare the data indicating the actual identifyingcharacteristic information associated with the product 190 a detected bythe first sensor 150 during movement of the product 190 a on the productadvancement surface 120 a to the data indicating the predefinedidentifying characteristic information associated with the product 190 ain order to determine an identity of the product 190 a detected by thefirst sensor 150. In other aspects, based on the inventory managementdata obtained from the electronic database 170 in association with agiven product 190 a, the control circuit 210 of the electronic inventorymanagement device 180 is programmed to compare the data indicating theactual physical characteristic information associated with the product190 a detected by the second sensor 155 during movement of the product190 a on the product advancement surface 120 a to the data indicatingthe predefined physical characteristic information associated with theproduct 190 a in order to verify that the identity and physicalcondition of the product 190 a detected by the second sensor 155 reflecta new and undamaged product 190 a.

In some embodiments, the control circuit 210 of the electronic inventorymanagement device 180 is programmed, in response to a determination, bythe electronic inventory management device 180, that a verification ofthe identity of the product 190 a failed, or that the product 190 a isnot in a new condition, or is in a damaged condition, or is not beingtransported in storage conditions (e.g., suitable temperature) suitablefor the product 190 a, to transmit an electronic error message to anelectronic device of a worker at the product distribution facility. Inone aspect, the control circuit 210 of the electronic inventorymanagement device 180 is programmed, in response to a determination, bythe electronic inventory management device 180, that a verification ofthe identity of the product 190 a failed, or that the product 190 a isnot in a new condition, or is in a damaged condition, or is not beingtransported in storage conditions (e.g., suitable temperature) suitablefor the product 190 a, to redirect movement of the product 190 adetected by the sensors 150, 155 and/or 160 on the product advancementsurface 120 a of the conveyor 110 a.

In some aspects, the control circuit 210 of the electronic inventorymanagement device 180 is programmed to compare actual route informationof the product 190 a based on detection of the product 190 a by thesensor 160 to the predefined route information associated with theproduct 190 a in the electronic database 170 and to redirect movement ofthe product 190 a on the product advancement surface 120 a of theconveyor 110 in response to a determination that the actual route of theproduct 190 a moving on the product advancement surface 120 a of theconveyor 110 a is not consistent with the predefined route informationassociated with the product 190 a that was obtained from the electronicdatabase 170. In one aspect, the control circuit 210 of the electronicinventory management device 180 is programmed, in response to thedetermination by the control circuit 210 of the electronic inventorymanagement device 180 that the actual route of the product 190 a movingon the product advancement surface 120 a of the conveyor 110 a isinconsistent with the route information associated with the product 190a, to transmit an electronic error message to an electronic device of aworker at the product distribution facility.

In one aspect, a redirection of the product 190 a from conveyor 110 a toconveyor 110 b and/or then to conveyor 110 c is effectuated via theelectronic inventory management device 180 sending a signal via thenetwork 115 to the conveyor control unit 140 a. In response to receiptof such a signal by the conveyor control unit 140 a, the conveyorcontrol unit 140 a causes the redirection of the product 190 from theproduct advancement surface 120 a of conveyor 110 a to the productadvancement surface 120 b of conveyor 110 b at the transfer nodeprovided via transfer conveyor 130 a. It will be appreciated that theredirection of the product 190 a from the conveyor 110 a to the conveyor110 b is effectuated, in some configurations, via a transfer conveyorcontrol unit coupled directly to the transfer conveyor 130 a, and whichmay receive a redirection-requiring signal either from the conveyorcontrol unit 140 a, or directly from the electronic inventory managementdevice 180.

In some embodiments, the display screen 260 of the electronic inventorymanagement device 180 is configured to display various graphicalinterface-based menus, options, and/or alerts that may be transmittedfrom and/or to the electronic inventory management device 180 inconnection with various aspects of receiving electronic data from thesensors 150, 155, 166 and/or from the electronic database 170 and/or therouting/rerouting of the products 190 a-190 c on the conveyors 110 a-110c. The inputs 270 of the electronic inventory management device 180 maybe configured to permit an operator to navigate through the on-screenmenus on the electronic inventory management device 180 and make changesand/or updates to the routes of the products 190 a-190 c and/or causetransfers of products 190 a-190 c between conveyors 110 a-110 c. It willbe appreciated that the display screen 260 may be configured as both adisplay screen and an input 270 (e.g., a touch-screen that permits anoperator to press on the display screen 260 to enter text and/or executecommands.)

FIG. 3 shows an embodiment of an exemplary method 300 of sorting andtracking products 190 a-190 c at a product distribution facility. Themethod 300 includes providing interconnected conveyors 110 a-110 cconfigured to move products 190 a-190 c (step 310). As described above,the conveyors 110 a-110 c of FIG. 1 can be horizontally adjacent orvertically stacked relative to one another and include one or moreconveyors 130 a and 130 b interconnecting the conveyors 110 a-110 c andproviding multiple transfer nodes where the products 190 a-190 c may betransferred between the conveyors 110 a-110 c. In some aspects, theconveyors 110 a-110 c and the transfer conveyors 130 a-130 b areindependently movable relative to one another.

The method 300 of FIG. 3 further includes providing a first sensor 150positioned proximate a product advancement surface 120 a of at least oneof the conveyors 110 a and configured to detect at least one identifyingcharacteristic of at least one product 190 a moving on the productadvancement surface 120 a (step 320). As described above, such a sensor150 can include but is not limited to a motion-detecting sensor, a photosensor, a radio frequency identification (RFID) sensor, an opticalsensor, a barcode sensor, and a digital camera sensor.

The method 300 of FIG. 3 further includes providing a second sensor 155positioned proximate the product advancement surface 120 a andconfigured to detect at least one physical characteristic of the atleast one product 190 a moving on the product advancement surface 120(step 330). As described above, such a sensor 155 can include but is notlimited to a weight sensor, a volumetric sensor, size sensor, a 3-Dsensor, a gas/chemical sensor, an infrared sensor, a thermal sensor, orthe like.

As discussed above, as the product 190 a moves along the productadvancement surface 120 a of conveyor 110 a, the product 190 a isdetected by the first and second sensors 150 and 155. In one aspect, thefirst sensor 150 detects one or more identifying characteristicsassociated with the product 190 (e.g., bar code, RFID, etc.) while thesecond sensor 155 detects one or more physical characteristics of theproduct 190 a (e.g., size, weight, shape, temperature etc.). In someaspects, the method 300 can include providing a third sensor 160positioned proximate the product advancement surface 120 a andconfigured to detect a location or a presence of the product 190 amoving on the product advancement surface 120 a. For example, in oneaspect, the third sensor 160 is a motion-detecting sensor that detectsthe presence of the product 190 a on the product advancement surface 120a and activates (either directly, or via the electronic inventorymanagement device 180) one or more of the first and second sensors 150and 155 in order to facilitate the scanning of the identifying andphysical characteristics of the product 190 a.

As discussed above, the electronic data obtained by the sensors 150,155, and 160 is transmitted over the network 115 to an electronicdatabase 170 for storage and is available for retrieval by theelectronic inventory management device 180. To that end, the exemplarymethod 300 of FIG. 3 includes providing an electronic database 170 forstoring inventory management data (step 340). As described above, theexemplary electronic database 170 stores electronic data associated withthe products 190 a-190 c moving on the conveyors 110 a-110 c, whichincludes but is not limited to data that indicates: one or morepredefined identifying characteristics associated with the products 190a-190 c; one or more predefined physical characteristic associated withthe products 190 a-190 c; actual identifying characteristic informationassociated with the products 190 a-190 c; and actual physicalcharacteristic information associated with the products 190 a-190 c.

As explained above, the actual identifying characteristic (e.g.,barcode, RFID, etc.) information stored in the electronic databasecorresponds to electronic data acquired by the sensor 150 upon scanningthe products 190 a-190 c and transmitted by the sensor 150 to theelectronic database 170 over the network 115. Similarly, the actualphysical characteristic (e.g., weight, size, shape, temperature etc.)information stored in the electronic database 170 corresponds toelectronic data acquired by the sensor 155 upon scanning the products190 a-190 c and transmitted by the sensor 155 to the electronic database170 over the network 115. The predefined identifying characteristicassociated with the products 190 a-190 c stored in the electronicdatabase 170 corresponds to an electronic identifier complementary tothe RFID, barcode, or other identifier present on the products 190 a-190c. The predefined physical characteristic associated with the products190 a-190 c stored in the electronic database 170 corresponds to defaultphysical characteristics (e.g., weight, size, shape, temperature) of theproducts 190 a-190 c when they are in a new and undamaged conditionsand/or at their desired or required storage temperature (e.g., topreserve freshness or desired shape). In some aspects the predefinedphysical characteristics associated with the products 190 a-190 c storedin the electronic database 170 also include tolerated thresholds (e.g.,percentages, degrees, etc.) that, if exceeded, would result in an errorsignal in association with a product 190 a and/or cause the product 190a to be diverted from conveyors 110 a to conveyor 110 b (e.g., forreturning to the product sorting area, for disposal, etc.).

The method 300 of FIG. 3 further includes providing a processor-basedelectronic inventory management device 180 in communication with thefirst sensor 150, second sensor 155, and electronic database 170 andconfigured obtain the inventory management data stored in the electronicdatabase 170 (step 350). In some aspects, based on the inventorymanagement data obtained from the electronic database 170 in associationwith the products 190 a-190 c, the electronic inventory managementdevice 180 compares the data indicating the actual identifyingcharacteristic information associated with the products 190 a-190 cdetected by the sensor 150 during movement of the products 190 a-190 con the product advancement surface 120 a-120 c to the data indicatingthe predefined identifying characteristic information associated withthe products 190 a-190 c in order to determine an identity of theproduct 190 a detected by the sensor 150. In other aspects, based on theinventory management data obtained from the electronic database 170 inassociation with the products 190 a-190 c, the electronic inventorymanagement device 180 compares the data indicating the actual physicalcharacteristic information associated with the products 190 a-190 cdetected by the sensor 155 during movement of the products 190 a-190 con the product advancement surface 120 a-120 c-to the data indicatingthe predefined physical characteristic information associated with theproducts 190 a-190 c in order to verify that the identity and physicalcondition of the products 190 a-190 c detected by the sensor 155 reflectnew and undamaged products 190 a-190 c at appropriate storagetemperatures.

As described above, if the aforementioned comparison of the actualidentifying and physical characteristic to the predefined identifyingand physical characteristic by the electronic inventory managementdevice 180 results in a determination, by the electronic inventorymanagement device 180, that a verification of the identity of theproduct 190 a failed, or that the product 190 a is not in a newcondition, or that the products 190 a is in a damaged condition, or thatthe products 190 a is not being transported at a temperature suitable tomaintain the freshness or physical integrity of the product 190 a, togenerate an electronic error message. Such an electronic error messagecan be transmitted by the electronic inventory management device 180over the network 115 to the electronic database 170 to create an errorrecord, or to an electronic device of a worker at the productdistribution facility to prompt the worker to take action. In someembodiments, if a verification of the identity of the product 190 afailed, or if the product 190 a is not in a new condition, or if theproduct 190 a is in a damaged condition, or if the product 190 a is notbeing transported at a temperature required for storing this product 190a, the electronic inventory management device 180 redirects movement ofthe product 190 a on the product advancement surface 120 a of theconveyor 110 a. In some aspects, a redirection of the product 190 a canbe effectuated via the electronic inventory management device 180sending a signal via the network 115 to the conveyor control unit 140 a,and the conveyor control unit 140 a, in response to receipt of such asignal, causing the redirection of the product 190 a from the productadvancement surface 120 a of conveyor 110 a to the product advancementsurface 120 b of conveyor 110 b at a transfer node provided by thetransfer conveyor 130 a.

In some embodiments, the data obtained by a weight sensor 155 isanalyzed by the electronic inventory management device 180 not only todetect physical anomalies (e.g., damage, spillage, etc.) associated witha product 190 a, but also to facilitate product packing optimization.For example, in one aspect, a product 190 a that is interpreted by thecontrol circuit 210 of the electronic inventory management device 180 asheavy item (i.e., because it exceeds a certain preset heavy itemthreshold, for example, 20 pounds, 50 pounds, 100 pounds, etc.) can bedirected by the electronic inventory management device 180 along theproduct advancement surface 120 a of the conveyor 110 a directly toloading, which facilitates the loading of the heavy items first (i.e.,at a bottom of a stack). In another aspect, the control circuit 210 ofthe electronic inventory management device 180 is programmed totemporarily divert products 190 a that are not considered heavy itemsfrom conveyor 110 a to a bypass conveyor (e.g., 110 b) in order to allowthe heavy items to pass first and arrive first at the output point ofconveyor 110 a to be loaded at a bottom of a stack, then to transfer thelighter items back to conveyor 110 a and permit the light items tocontinue traveling on conveyor 110 a to the output point, therebyfacilitating the workers at the product distribution facility in loadingthe heavier products 190 a first and the lighter products 190 a on topof the heavy products 190.

In some embodiments, an error condition associated with an inappropriatetemperature of a product 190 a sensed by a thermal/infrared sensor 155results in an optimizing redirection of the product 190 a from conveyor110 a to conveyor 110 b for transporting to a cold area. Such aredirection expedites the transporting of the temperature-sensitiveproduct 190 a along the conveyor 110 a to a delivery truck having afrozen and/or a refrigerated section. Such expediting is effectuated, insome aspects, by temporarily diverting, via a signal generated by thecontrol circuit 210 of the electronic inventory management device 180,products 190 a that are not temperature-sensitive from conveyor 110 a toa bypass conveyor (e.g., 110 b) in order to allow thetemperature-sensitive products 190 a to pass first and arrive first atthe output point of conveyor 110 a to be loaded into a frozen orrefrigerated section of a delivery vehicle, then to transfer thenon-temperature-sensitive products 190 a back to conveyor 110 a andpermit the non-temperature-sensitive products 190 a to continuetraveling on conveyor 110 a to the output point, thereby reducing thetravel time on the conveyor 110 a for temperature-sensitive products 190a.

In some embodiments, the data obtained by a 3-D sensor 155 is analyzedby the electronic inventory management device 180 not only to detectphysical anomalies (e.g., damage, spillage, deformation, etc.)associated with a product 190 a, but also to facilitate product packingoptimization. For example, in one aspect, a product 190 a that isinterpreted by the control circuit 210 of the electronic inventorymanagement device 180 as a large-sized item (i.e., because it exceeds acertain preset large item threshold) can be directed by the electronicinventory management device 180 along the product advancement surface120 a of the conveyor 110 a directly to loading, which facilitates theloading of the largest items first (i.e., at a bottom of a stack). Inanother aspect, the control circuit 210 of the electronic inventorymanagement device 180 is programmed to temporarily divert products 190 athat are considered small-sized items from conveyor 110 a to a bypassconveyor (e.g., 110 b) in order to allow the larger items to pass firstand arrive first at the output point of conveyor 110 a to be loaded at abottom of a stack, then to transfer the smaller-sized items back toconveyor 110 a and permit the smaller-sized items to continue travelingon conveyor 110 a to the output point, thereby facilitating the workersat the product distribution facility in loading the larger-sizedproducts 190 a first and the smaller-sized products 190 a on top of thelarger-sized products 190.

The systems and methods described herein advantageously include multipleconveyors for transporting products and multiple sensors configured totrack and identify the products moving on the conveyors, as well as todetect any damage, undesired storage condition, or another anomalyassociated with the products. The anomalies detected by the sensors inassociation with the products are analyzed by an electronic inventorymanagement device, which can redirect the products on the conveyors backto a staging area, where the products can be evaluated and/or repackagedand/or disposed, thereby advantageously preventing products that aredamaged or otherwise unsuited for use by the consumers from beingdelivered to the consumers. Accordingly, the methods and systemsdescribed herein advantageously reduce product returns by customers andthereby increase customer happiness and loyalty relative to theretailers and result in significant time and cost savings for productdistribution facility operators.

Those skilled in the art will recognize that a wide variety of othermodifications, alterations, and combinations can also be made withrespect to the above described embodiments without departing from thescope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

What is claimed is:
 1. A system for sorting and tracking products at aproduct distribution facility, the system comprising: a plurality ofinterconnected conveyors configured to move the products; a first sensorpositioned proximate a product advancement surface of at least one ofthe conveyors and configured to detect at least one identifyingcharacteristic of at least one product moving on the product advancementsurface; a second sensor positioned proximate the product advancementsurface and configured to detect at least one physical characteristic ofthe at least one product moving on the product advancement surface; aplurality of transfer nodes interconnecting the plurality of conveyors,each of the transfer nodes configured to permit transfer of the at leastone product from the product advancement surface of the at least one ofthe conveyors to the product advancement surface of another one of theconveyors; an electronic database storing inventory management dataincluding: data indicating predefined identifying characteristic andphysical characteristic information associated with the at least oneproduct, the predefined identifying characteristic and physicalcharacteristic information corresponding to the at least one productwhen in a new condition and undamaged; and data indicating actualidentifying characteristic information associated with the at least oneproduct, the actual identifying characteristic information correspondingto the at least one product when detected by the first sensor duringmovement of the at least one product along the product advancementsurface; data indicating actual physical characteristic informationassociated with the at least one product, the actual physicalcharacteristic information corresponding to the at least one productwhen detected by the second sensor during movement of the at least oneproduct along the product advancement surface; and a processor-basedelectronic inventory management device in communication with the firstand second sensors and the electronic database, the electronic inventorymanagement device being configured obtain the inventory management datastored in the electronic database and, based on the obtained inventorymanagement data, to: compare the data indicating the actual identifyingcharacteristic information associated with the at least one productdetected by the first sensor during movement on the product advancementsurface to the data indicating the predefined identifying characteristicinformation associated with the at least one product in order todetermine an identity of the at least one product detected by the firstsensor; compare the data indicating the actual physical characteristicinformation associated with the at least one product detected by thesecond sensor during movement on the product advancement surface to thedata indicating the predefined physical characteristic informationassociated with the at least one product in order to verify that theidentity of the at least one product and that the condition of the atleast one product detected by the second sensor is new and undamaged;and redirect movement of the at least one product detected by the firstand second sensors on the product advancement surface of the at leastone of the conveyors from the product advancement surface of the atleast one of the conveyors to the product advancement surface of theanother one the conveyors via at least one of the transfer nodes inresponse to a determination, by the electronic inventory managementdevice, that a verification of the identity of the at least one productfailed or that the at least one product is not in a new condition or isin a damaged condition.
 2. The system of claim 1, wherein the firstsensor includes at least one of a motion-detecting sensor, a photosensor, a radio frequency identification (RFID) sensor, an opticalsensor, a barcode sensor, and a digital camera sensor.
 3. The system ofclaim 1, wherein the second sensor includes at least one of a weightsensor, a volumetric sensor, and a size sensor.
 4. The system of claim1, further comprising a control unit coupled to the conveyors andconfigured to control directional movement of the conveyors, wherein theelectronic inventory management device is configured, in response to asuccessful verification of the identity of the at least one product andthat the at least one product is in a new and undamaged condition, totransmit a signal to the control unit to cause the control unit topermit the at least one product to continue moving on the productadvancement surface of the at least one of the conveyors without beingredirected.
 5. The system of claim 1, wherein the electronic inventorymanagement device is configured, in response to a determination, by theelectronic inventory management device, that a verification of theidentity of the at least one product failed or that the at least oneproduct is not in a new condition or is in a damaged condition, totransmit an electronic error message to an electronic device of a workerat the product distribution facility.
 6. The system of claim 1, furthercomprising a third sensor positioned proximate the product advancementsurface and configured to detect a location of the at least one productmoving on the product advancement surface; wherein the inventorymanagement data stored in the electronic database further includes dataindicating predefined route information associated with the at least oneproduct; and wherein the electronic inventory management device isconfigured to compare actual route information of the at least oneproduct based on detection of the at least one product by the thirdsensor to the predefined route information associated with the at leastone product in the electronic database in order to determine whether theactual route of the at least one product moving on the productadvancement surface of the at least one of the conveyors is consistentwith the predefined route information associated with the at least oneproduct.
 7. The system of claim 6, wherein the electronic inventorymanagement device, is configured, in response to a determination by theelectronic inventory management device that the actual route of the atleast one product moving on the product advancement surface of the atleast one of the conveyors is inconsistent with the predefined routeinformation associated with the at least one product in the electronicdatabase, to redirect movement of the at least one product along theproduct advancement surface onto a path consistent with the predefinedroute information associated with the at least one product.
 8. Thesystem of claim 7, wherein the electronic inventory management device isconfigured to redirect the route of the at least one product onto thepath consistent with the route information associated with the at leastone product via at least one of the transfer nodes.
 9. The system ofclaim 7, wherein the electronic inventory management device isconfigured, in response to the determination by the electronic inventorymanagement device that the actual route of the at least one productmoving on the product advancement surface of the at least one of theconveyors is inconsistent with the route information associated with theat least one product, to transmit an electronic error message to anelectronic device of a worker at the product distribution facility. 10.The system of claim 1, wherein the electronic database further includesorder information associated with the at least one product moving on theproduct advancement surface, and wherein the electronic inventorymanagement device is further configured to obtain the order informationassociated with the at least one product from the electronic databaseafter a successful verification by the electronic inventory managementdevice of the identity of the at least one product and that the at leastone product is in a new and undamaged condition, and to determinewhether the verified identity of the at least one product moving on theproduct advancement surface of the at least one of the conveyors isconsistent with the order information associated with the at least oneproduct obtained by the electronic inventory management device from theelectronic database.
 11. A method for sorting and tracking products at aproduct distribution facility, the method comprising: providing aplurality of interconnected conveyors configured to move the products;providing a first sensor positioned proximate a product advancementsurface of at least one of the conveyors and configured to detect atleast one identifying characteristic of at least one product moving onthe product advancement surface; providing a second sensor positionedproximate the product advancement surface and configured to detect atleast one physical characteristic of the at least one product moving onthe product advancement surface; providing a plurality of transfer nodesinterconnecting the plurality of conveyors, each of the transfer nodesconfigured to permit transfer of the at least one product from theproduct advancement surface of the at least one of the conveyors to theproduct advancement surface of another one of the conveyors; providingan electronic database storing inventory management data including: dataindicating predefined identifying characteristic and physicalcharacteristic information associated with the at least one product, thepredefined identifying characteristic and physical characteristicinformation corresponding to the at least one product when in a newcondition and undamaged; and data indicating actual identifyingcharacteristic information associated with the at least one product, theactual identifying characteristic information corresponding to the atleast one product when detected by the first sensor during movement ofthe at least one product along the product advancement surface; dataindicating actual physical characteristic information associated withthe at least one product, the actual physical characteristic informationcorresponding to the at least one product when detected by the secondsensor during movement of the at least one product along the productadvancement surface; and providing a processor-based electronicinventory management device in communication with the first and secondsensors and the electronic database, the electronic inventory managementdevice being configured obtain the inventory management data stored inthe electronic database and, based on the obtained inventory managementdata, to: compare the data indicating the actual identifyingcharacteristic information associated with the at least one productdetected by the first sensor during movement on the product advancementsurface to the data indicating the predefined identifying characteristicinformation associated with the at least one product in order todetermine an identity of the at least one product detected by the firstsensor; compare the data indicating the actual physical characteristicinformation associated with the at least one product detected by thesecond sensor during movement on the product advancement surface to thedata indicating the predefined physical characteristic informationassociated with the at least one product in order to verify that theidentity of the at least one product and that the condition of the atleast one product detected by the second sensor is new and undamaged;and redirect movement of the at least one product detected by the firstand second sensors on the product advancement surface of the at leastone of the conveyors from the product advancement surface of the atleast one of the conveyors to the product advancement surface of theanother one the conveyors via at least one of the transfer nodes inresponse to a determination, by the electronic inventory managementdevice, that a verification of the identity of the at least one productfailed or that the at least one product is not in a new condition or isin a damaged condition.
 12. The method of claim 11, wherein the firstsensor includes at least one of a motion-detecting sensor, a photosensor, a radio frequency identification (RFID) sensor, an opticalsensor, a barcode sensor, and a digital camera sensor.
 13. The method ofclaim 11, wherein the second sensor includes at least one of a weightsensor, a volumetric sensor, and a size sensor.
 14. The method of claim11, further comprising: providing a control unit coupled to theconveyors and configured to control directional movement of theconveyors; and transmitting, via the electronic inventory managementdevice and in response to a successful verification of the identity ofthe at least one product and that the at least one product is in a newand undamaged condition, a signal to the control unit to cause thecontrol unit to permit the at least one product to continue moving onthe product advancement surface of the at least one of the conveyorswithout being redirected.
 15. The method of claim 11, further comprisingtransmitting, via the electronic inventory management device and inresponse to a determination, by the electronic inventory managementdevice, that a verification of the identity of the at least one productfailed or that the at least one product is not in a new condition or isin a damaged condition, an electronic error message to an electronicdevice of a worker at the product distribution facility.
 16. The methodof claim 11, further comprising: providing a third sensor positionedproximate the product advancement surface and configured to detect alocation of the at least one product moving on the product advancementsurface; storing, on the electronic database, data indicating predefinedroute information associated with the at least one product; andcomparing, via the electronic inventory management device actual routeinformation of the at least one product based on detection of the atleast one product by the third sensor to the predefined routeinformation associated with the at least one product in the electronicdatabase in order to determine whether the actual route of the at leastone product moving on the product advancement surface of the at leastone of the conveyors is consistent with the predefined route informationassociated with the at least one product.
 17. The method of claim 16,further comprising redirecting, via the electronic inventory managementdevice and in response to a determination by the electronic inventorymanagement device that the actual route of the at least one productmoving on the product advancement surface of the at least one of theconveyors is inconsistent with the predefined route informationassociated with the at least one product in the electronic database,movement of the at least one product along the product advancementsurface onto a path consistent with the predefined route informationassociated with the at least one product.
 18. The method of claim 17,further comprising: redirecting, via the electronic inventory managementdevice, the route of the at least one product onto the path consistentwith the route information associated with the at least one product viaat least one of the transfer nodes.
 19. The method of claim 17, furthercomprising transmitting, via the electronic inventory management deviceand in response to the determination by the electronic inventorymanagement device that the actual route of the at least one productmoving on the product advancement surface of the at least one of theconveyors is inconsistent with the route information associated with theat least one product, an electronic error message to an electronicdevice of a worker at the product distribution facility.
 20. The methodof claim 11, further comprising: storing, on the electronic database,order information associated with the at least one product moving on theproduct advancement surface; obtaining, via the electronic inventorymanagement device, the order information associated with the at leastone product from the electronic database after a successful verificationby the electronic inventory management device of the identity of the atleast one product and that the at least one product is in a new andundamaged condition; and determining, via the electronic inventorymanagement device, whether the verified identity of the at least oneproduct moving on the product advancement surface of the at least one ofthe conveyors is consistent with the order information associated withthe at least one product obtained by the electronic inventory managementdevice from the electronic database.